Interconnecting means for poles of circuit breakers

ABSTRACT

A multiphase molded case circuit breaker of high current rating is provided with an individual spring powered operating mechanism for each phase. These mechanisms and the movable contact structures operated thereby are secured to the base of the circuit breaker housing. Thereafter, all mechanism and contact pressure adjustments are made and all thermal and magnetic trip calibrations are set prior to mechanically interconnecting the movable contact structures by a removable connector bar that is driven axially through aligned tubular elements of the movable contact structures.

United States Patent 1191 Strobel 1451 Apr. 9, 1974 INTERCONNECTING MEANS FOR POLES OF CIRCUIT BREAKERS [75] Inventor: Albert Strobel, Cherry Hill, NJ. [73] Assignee: I-T-E Imperial Corporation,

Philadelphia, Pa.

[22] Filed: July 27, 1972 [21] Appl. No.: 275,577

[52] US. Cl. 29/628, 29/630 C [51] Int. Cl H01! 43/00 [58] Field of Search 29/628; 335/8, 9, 10

[56] References Cited UNITED STATES PATENTS 3,125,653 3/1964 Cole et al. 335/10 2,067,935 1/1937 Lingal 1 335/9 3,258,561 6/1966 Maicr 335/9 3,6()l.724 8/1971 Dietz i 335/8 3,329,912 7/1967 Brackett.... 335/8 2,056,020 9/1936 Schofield... 335/9 2,050,285 8/1936 Dorfman 335/9 2/1966 Poulton 335/10 4/1935 Graves et a1 335/9 Primary Examiner-Charles W. Lanham Assistant Examiner-James R. Duzan Attorney, Agent, or Firm-Ostro1enk, Farber, Gerb & Soffen 5 7] ABSTRACT 8 Claims, 4 Drawing Figures 7 '1 PATENTEDAPR 9 I974 SHEET 3 {1F 4 INTERCONNECTING MEANS FOR POLES OF CIRCUIT BREAKERS dium and moderately high current ratings, the movable contact carrier for each phase thereof is usually U- shaped and is connected to a single spring-powered operating mechanism by means of an insulated connector bar. Typically, this connector bar is rigidly assembled to each contact carrier by means of a metal clamping piece, such as a U-shaped clamp, that is staked or bolted to the connector bar, with this assembly taking place prior to mounting the movable contact structure in the circuit breaker housing.

Even though this arrangement has appeared satisfactory for multiphase breakers using a single springpowered mechanism for operating all phases, this arrangement presents certain difficulties in the case of circuit breakers having very high continuous current ratings, say at least 2,000 amperes at 600 volts. In order to achieve satisfactory operation of circuit breakers at very high currents, it is necessary to provide large contact areas and relatively strong contact pressure springs. This can be-achieved in a compact structure by providing multiple main contacts and an individual spring powered operating mechanism for each phase of the circuit breaker. However, because of bulk, proportions, and weight of the operating mechanism, it becomes quite cumbersome to assemble the breaker if the connector bar is mounted to all of the operating mechanisms before these mechanisms are mounted within the circuit breaker housing. In addition, once the connecter bar is mounted to interconnect all of the movable contact mechanisms, individual mechanism adjustments within the breaker are no longer possible since all operating mechanisms must then be operated simultaneously any time an adjustment of a single phase is required.

To overcome these difficuties, the instant invention provides a removable connector bar that is driven axially into aligned tubular elements of the contact carriers of all circuit breaker phases subsequent to mounting of the mechanisms within the housing and after adjustment of these mechanisms. Thus, the mechanism for each circuit breaker phase is handled individually through all assembly operations, it is mounted individually to the breaker housing, and all necessary adjustments are performed on each mechanism after mounting thereof in the housing without the necessity of operating the other mechanism. In the event trouble develops in the mechanism of one phase, this mechanism" may be removed and replaced individually, rather than Still another object is to provide a method of this type in which the connector bar is driven axially into aligned tubular members secured to the contact bridges of all phases.

These objects as well as other objects of this invention will become readily apparent after reading the following description of the accompanying drawings in which: 7

FIG. 1 is a plan view of a circuit breaker constructed in accordance with teachings of the instant invention.

FIG. 2 is a longitudinal cross-section taken through line 2-2 of FIG. 1, looking in the direction of arrows 2-2 and including a handle operating mechanism, not shown in FIG. 1.

FIG. 3 is an exploded perspective of one overcenter toggle mechanism and selected elements connected thereto. I

FIG. 4 is an exploded perspective of the movable contact structure for one phase.

Now referring to the figures. Three phase molded case circuit breaker of FIGS. 1 and 2 includes an individual overcenter spring-powered toggle operating mechanism. Prior art examples of circuit breakers having more than a single operating mechanism for all phases are disclosed in US. Pat. Nos. 2,067,935 and 3,125,653.

Circuit breaker 25 includes a molded housing constructed of base 26 and removable cover 27 joined along line 28, and provided with longitudinal internal partitions 31, 32 which divide housing 26, 27 into three longitudinally extending compartments, one for each phase of circuit breaker 25. Cover 27 is provided with aperture 29 through which stubby bifurcated extension 33 of operating handle means 30 extends. Each section of handle extension 33 receives an individual pin 34 extending upwardly from the web portion of inverted generally U-shaped operating yoke member 35 of the center phase. Operating members 35 of the outer phases are each secured to handle means 30 by a pair of screws 152.

Member 35 is pivoted to the spaced arms of generally U-shaped operating mechanism frame 36 at outwardly extending lugs 37. Bolts 48, received by threaded apertures of intumed edges 36a at the bottom of frame 36, fixedly secure the latter to base 26. Transverse tie member 49 is riveted to the arms of frame 36 to maintain spacing therebetween and to stabilize the frame structure.

Four-tensioned coil springs 38, each connected at one end thereof to the web of operating member 35, combine to constitute the main operating spring means for the overcenter toggle-type contact operating mechanism. The outer ends of springs 38 are connected to spaced plates 39, 39 that are pivotally mounted to toggle knee pin 4] connecting upper 42 and lower 43 toggle links. The upper ends of upper toggle links 42 are pivotally connected to the spaced arms of latchable cradle at pins 44, and the lower ends of lower toggle links 43 are pivotally connected to contact carrier 45 by rod 46 that extends between the spaced arms of contact carrier 45. The spaced arms of cradle 40 are positioned adjacent the inner surfaces of the spaced arms of frame 36 and are pivotally connected thereto by pins 47 that are secured to frame 36.

Under normal operating conditions plate 51, secured to web 40a of cradle 40, is in engagement with forward latching surface 52 of auxiliary latch 53. The latter is loosely mounted to pivot rod 55 extending between the spaced arm of mechanism frame 36 and slightly outboard thereof. The coiled end sections of torsion spring member 56 are wound about pivot rod 55, with the ends of these sections bearing against rod 57 and auxiliary latch 53 to bias the latter counterclockwise against stop rod 58. The ends of rods 57 and 58 are supported by the arms of frame 36. Leaf spring 73 secured to auxiliary latch 53 bears against pivot rod 55 biasing latch 53, so that rod 55 will normally lie at the central portion of V-shaped notch 74 of primary latch 53.

The ends of rod 55 projecting outboard of mechanism frame 3y are engaged by the hooked portions at the forward extensions 59 of the arms for U-shaped trip unit frame 60, whose web portion is seated on a forward surface of load strap 61, being secured thereto by bolts 62 that extend through clearance apertures in strap 61 and are received by threaded inserts molded in base 26.

Rear latch tip 54 engages latch tip 73 at the U-shaped forward arm of primary latch 65, whose rear latch tip 64 is engaged by latch plate 67 mounted on one leg of L-shaped carrier 66. Primary latch 65 is pivotally mounted to trip unit frame 60 at stub shaft 69, and the carrier is pivoted on rod 68 to frame 60. Tension spring 75 biases primary latch 65 in a clockwise direction about pivot 69. The other leg of carrier 66 is provided with transversely extending pin 71 that projects into triangular window 72 of primary latch 65 at a portion thereof near rear latch tip 64, for a reason to be hereinafter explained. Tension spring 76, connected between frame 60 and carrier extension 66a, biases carrier 66 in a counterclockwise direction about its pivot 68 toward latching position.

When automatic tripping occurs, carrier 66 in the faulted phase is moved clockwise either by the deflection of bimetal 77 or movement of magnetic armature 78, causing latch plate 67 to release primary latch 65, which in turn releases secondary latch 53 and permits main operating springs 38 to rotate cradle 40 in a counterclockwise direction to break toggle 42, 43. The force from main spring 38 acts through cradle 40, primary latch 53, and secondary latch 65 to drive cam surface 78, bounding opening 72, against extension 71 to rotate carrier 66 clockwise, with surface 79 thereof engaging ear 81 of extension 82 on tripper bar 80 which extends between all three phases. This causes tripper bar 80 to rotate in a counterclockwise direction, so that extensions 82 in the non-faulted phases rotate counterclockwise with cam surfaces 83 thereof engaging transversely extending pin 84 of carriers 66 in the non-faulted phases, rotating them clockwise or in the tripping direction, to release the cradle latching systems in the non-faulted phases, so that the contacts of all three phases are open.

In order to prevent closing of the contacts of any one phase before the operating mechanisms of all phases are latched, circuit breaker 25 is provided with a defeater latching system including defeater latch 80 and defeater lever 90. Latch 80 is pivotally mounted upon rod 55 and includes protrusion 81' extending over the rear of cradle 40 when the latter is in latched position. Latch 80' further includes protrusion 82' extending over the forward end of defeater lever 90 in slot 91 thereof. Coiled tension spring 83 is connected between stop rod 57 and latch 80, passing partially around rod 55, to bias latch in a counterclockwise direction about its pivot 55 and maintaining this pivot in the basic position at the right end of slot 84' in latch 80'. This basic position is established through the engagement of latch stop surface 86 and stop rod 57.

Slot 91 is in the web of the U-shaped forward portion of latch lever 90, with the U arms having pivot pin 69 for lever extending therethrough. Rear portion 89 of lever 90 is positioned below and in interfering relationship with transverse pin 71 mounted to latch plate carrier 66. I

During normal relatching of circuit breaker 25, inwardly protruding portions of the operating member 35 arms engage outboard portions of pin 44 to pivot cradle 40 clockwise, whereby the latter cams defeater latch 80 away and moves below auxiliary latch 53. Upon release of the circuit breaker operating handle 30, the elements of the latch train 53, 65, 66 move into place. However, should any of these elements fail to properly engage or should cradle 40 not have been moved far enough to engage auxiliary latch 53, cradle 40 will pick up defeater latch protrusion 81, causing clockwise rotation of defeater latch 80. In turn, this causes defeater latch protrusion 82' to engage defeater lever 90 and rotate the latter counterclockwise, with the rear end 89 thereof contacting carrier extension 71 so that latch plate carrier 66 is pivoted in a clockwise or latch train releasing direction. This releasing movement of carrier 66 is amplified through the movement of cradle 40 acting through the auxiliary and primary latches 53, 65, so that carrier surface 79 engages nose 81 0s trip bar extension 82 to rotate common tripper bar 80 in a counterclockwise direction, thereby causing the latch systems of all other phases to be released.

The lower end of bimetal 77 is fixedly secured to shading coil 99, and those elements are fixedly secured to molded frame member secured to trip unit frame 60. The horizontal leg of inverted U-shaped stationary magnetic frame member 98 passes through the center of coil 99. Member 98 is secured to the rear of frame 60, with the vertical legs of member 98 being on opposite sides of load strap 61. The other U-shaped magnetic frame member 96 is secured directly to load strap 61, with the ends of the arms for frame members 96 and 98 confronting one another in spaced relationship. Thus, current flowing in load strap 61 generates flux in magnetic frame 96, 98 which induces current flow in shading coil 99 and thereby generates heat that is conducted to bimetal 77 for heating thereof. Coiled tension spring 97, connected between armature 78 and an element mounted to the rear transverse part 60a of frame 60, biases the former away from two spaced legs 98a extending upward from the horizontal leg of member 98, and is drawn downward toward legs 98a when overload currents generate sufficient magnetic flux in magnetic frame 78, 96, 98.

With particular reference to FIG. 4, it is seen that the movable contact structure for each phase of circuit breaker 25 includes eight main contacts 103-110 and a single arcing contact 101. The latter contact 101 is mounted at the forward end of arm 112, which is pivotally mounted to carrier 45 at toggle connecting rod 46. Main contacts 103-110 are arranged in two parallel rows positioned to the rear of arcing contact 101 and disposed at right angles to the plane of movement of arcing contact arm 112.

Main contacts 103-106 in the forward row are mounted. to individual contact arms 113-116 respectively, all pivotally mounted to carrier 45 on rod 46. Main contacts 107-1 in the rear row are mounted to the forward end of the respective contact arms 117-120, respectively, pivotally mounted to carrier 45 on rod 102. All of the contact arms 112-120 are connected to load strap 61 by means of individual stacks 121 of flexible sheet conductors. Contact arms 113-116 are in alignment with and extend over the respective contact arms 1 17-120, so that the latter group of arms 117-120 block downward movement of the former group of arms 113-116 to establish the open circuit position of contacts 103-106 in a manner which will hereinafter be seen. The open circuit position for arcing contact arm 112 is established through engagement thereof with aligned pins 123, 124 which mount the respective pairs of main contacts 1 17, 118 and 119, 120 to auxiliary carriers 125, 126 respectively. Notch 122 along the lower edge of arcing contact arm 112 provides clearance for pins 123, 124.

Auxiliary carrier 125 is an inverted U-shaped memher whose arms extend downwardly through cutouts 131, 132 in the web portion of contact carrier 45 and straddle four contact arms 113, 114, 117, 118. Pin 123 secures contacts 117, 1 18 to the lower ends of the arms comprising auxiliary carrier 125. The web of auxiliary carrier 125 is biased towards the web of contact carrier 45 by coiled compression spring 127, which is wound around the threaded body of bolt 128 whose head is positioned below the web portions of contact carrier 45. Self-locking nut 133 mounted to bolt 128 is rotated to adjust the loading of spring 127, with the rectangular shoulder of bolt 128 cooperating with rectangular cutout in carrier 45 to prevent rotation of bolt 128. Thus, in the open circuit position, sprkng 127 biases the web of auxiliary contact carrier 125 against the web of contact carrier 45, and when the contacts are closed there is a space between the webs of these contact carriers 45, 125, so that the force exerted by spring 127 acts to bias contacts 107, 108 into firm electrical engagement with their respective cooperating contact portions on line strap 136.

The mounting of contact arms 119, 120 to auxiliary contact carrier 126 and mounting of the latter to contact carrier 45 is the same as the mounting of contact arms 1 17, 118 and auxiliary carrier 125, so that this description will not be repeated.

Biasing forces for each of the contacts 103-106 in the forward row are provided by individual coiled compression springs 138, and each of these springs is mounted in the same way so that only the mounting of one of these springs will be described. The lower end of spring 138 extends into depression 139 in the upper surface of main contact arm 113, and the rear of spring 138 extends into tubular support 141 through the open bottom thereof. Support 141 is mounted to the upper surface of carrier 45 at the web portion thereof, and its upper end is threaded to receive adjusting screw 142 whose lower end bears against disc 143 abutting the upper end of spring 138. If screw 142 is adjusted to set the contact pressure exerted by spring 138, lock nut 144 is tightened to lock this adjustment.

In order to increase the area of engagement between main contacts 103-110 and their respective cooperating stationary main contacts in the very limited space available, it is noted that each of the main contacts is provided with a portion extending outward of its respective contact arm. That is, in order to utilize the space below arcing contact 112, main contacts 104, 105, 108, 109 have been exended beyond their respective contact arms 114, 115, 118, 119 to project below arcing contact arm 112. Similarly, main contacts 103, 106, 107, have been extended] outboard from their respective contact arms 1 13, l 16, 1 17, 120, to lie in the space below the outboard arms of auxiliary contact carrier 125, 126and other elements used tov connect the movable contact structure to the contact operating mechanism.

- The forward end of arcing contact arm 112 is biased downward away from the web portion or contact carrier 45 by coiled compresion spring 171 whose lower end is positioned by pin 172 extending uwpard from arm 112. The upper end of spring 171 extends into tubular member 173, on the upper surface of the carrier 45 web portion, through the bottom of member 173 and abuts the closed upper end thereof.

The spaced arms of contact carrier 45 are provided with rearward extensions 45a, 45b that are spaced by and secured to shouldered cylindrical tube 146. After all contact structures, operating mechanisms, latching devices, and automatic trip units are mounted to base 26, and all adjustments to these mechanisms have been made, the contact structures of all phases are operated to the closed circuit position, so that the tubular members 146 of all phases are axially aligned and are positioned, above barriers 31, 32 and the longitudinal sides of base 26. Thereafter, cylindrical tie bar 147 isdriven longitudinally in the members 146 of all phases to constitute a rigid mechanical connection between the movable contact structures of all phases. The fit between tie rod 147 and tubular members 146 is tight enough to prevent unintentional axial movement of tie rod 147, yet permits tie rod 147 to be removed for convenient servicing and replacement of parts. Mechanism frame 36 is provided with aligned elongated slots 148 to provide clearances for movement of rod 147 during opening and closing of the movable contact structures.

It is noted that because of high magnitude current flow in circuit breaker 25, the magnetic fields generated are very strong. In order to reduce adverse effects of these magnetic fields, many of the frame parts and operating mechanism parts are constructed of nonmagnetic stainless. steel.

For those features of construction in circuit breaker 25 that have not been described in detail herein, reference is made to one or more of the copending applications Serial Nos. 275,568, 275,446, 275,578, 275,507, 275,454, 275,508, 275,621, 275,623, 275,624, 275,569, 275,522, 275,521, 275,523, and 275,622, all filed of even date herewith, and all assigned to the assignee of the instant invention.

. Although there has been described a preferred embodiment of this novel invention, many variations and modifications will now become apparent to those skilled in the art. Therefore, this invention is to be limited not by the specific disclosure herein but only by the appending claims.

The embodiments of the invention in which an exclusive privilege or property is claimed are defined as follows.

1. A method for constructing a multipole circuit breaker having an individual movable contact assembly for each pole thereof and a housing wherein said movable contact assemblies are disposed, said method including the steps of individually placing said movable contact assemblies within said housing in their operative positions, fixedly securing portions of said movable contact assemblies to said housing, individually adjusting contact pressures for each of said assemblies, and thereafter interconnecting movable portions of said movable contact assemblies to each other for simultaneous operation.

2. A method as set forth in claim 1 in which the circuit breaker also includes an individual spring powered operating mechanism connected to each of said movable contact assemblies for moving the movable portions thereof between circuit open and close positions, and wherein said interconnecting movable portions of said movable contact assemblies affect interconnection of said spring operating mechanisms.

3. A method as set forth in claim 1' in which said interconnecting movable portions of the movable contact assemblies are affected by inserting an insulating rod into aligned openings in'each of said movable contact assemblies.

4. A method as set forth in claim 1 in which said interconnecting movable portions of the movable contact assemblies are affected by inserting a rigid rod axially into aligned openings in each of said movable contact assemblies to force fit said rod in at least some of said openings.

5. A method as set forth in claim 1 in which said interconnecting movable portions of the movable contact assemblies are affected by inserting a rigid insulating rod axially into axially aligned tubes in said movable portions of each of said movable contact assemblies.

6. A method as set forth in claim 1 in which said interconnecting movable portions of the movable contact assemblies are affected by driving an insulating rod axially into aligned openings in each of said movable contact assemblies.

7. A method as set forth in claim 6 in which the circuit breaker also includes an individual spring powered operating mechanism connected to each of said movable contact assemblies for moving the movable portions thereof between circuit open and close positions, and wherein said interconnecting movable portions of said movable contact assemblies affect interconnection of said spring operating mechanisms.

8. A method as set forthin claim 1 also including a step of operating the movable contact assemblies to circuit closed positions prior to said interconnecting movable portions of said movable contact assemblies and maintaining in said circuit closed positions during said interconnecting movable portions of said movable contact assemblies. 

1. A method for constructing a multipole circuit breaker having an individual movable contact assembly for each pole thereof and a housing wherein said movable contact assemblies are disposed, said method including the steps of individually placing said movable contact assemblies within said housing in their operative positions, fixedly securing portions of said movable contact assemblies to said housing, individually adjusting contact pressures for each of said assemblies, and thereafter interconnecting movable portions of said movable contact assemblies to each other for simultaneous operation.
 2. A method as set forth in claim 1 in which the circuit breaker also includes an individual spring powered operating mechanism connected to each of said movable contact assemblies for moving the movable portions thereof between circuit open and close positions, and wherein said interconnecting movable portions of said movable contact assemblies affect interconnection of said spring operating mechanisms.
 3. A method as set forth in claim 1 in which said interconnecting movable portions of the movable contact assemblies are affected by inserting an insulating rod into aligned openings in each of said movable contact assemblies.
 4. A method as set forth in claim 1 in which said interconnecting movable portions of the movable contact assemblies are affected by inserting a rigid rod axially into aligned openings in each of said movable contact assemblies to force fit said rod in at least some of said openings.
 5. A method as set forth in claim 1 in which said interconnecting movable portions of the movable contact assemblies are affected by inserting a rigid insulating rod axially into axially aligned tubes in said movable portions of each of said movable contact assemblies.
 6. A method as set forth in claim 1 in which said interconnecting movable portions of the movable contact assemblies are affected by driving an insulating rod axially into aligned openings in each of said movable contact assemblies.
 7. A method as set forth in claim 6 in which the circuit breaker also includes an individual spring powered operating mechanism connected to each of said movable contact assemblies for moving the movable portions thereof between circuit open and close positionS, and wherein said interconnecting movable portions of said movable contact assemblies affect interconnection of said spring operating mechanisms.
 8. A method as set forth in claim 1 also including a step of operating the movable contact assemblies to circuit closed positions prior to said interconnecting movable portions of said movable contact assemblies and maintaining in said circuit closed positions during said interconnecting movable portions of said movable contact assemblies. 